U.S. patent number 6,401,245 [Application Number 09/777,577] was granted by the patent office on 2002-06-11 for knee pad and manufacturing method.
This patent grant is currently assigned to FLA Orthopedics, Inc.. Invention is credited to E. Gerald Slautterback.
United States Patent |
6,401,245 |
Slautterback |
June 11, 2002 |
Knee pad and manufacturing method
Abstract
An improved knee pad for industrial applications that require
kneeling, which has an outer shell, an inner cushion pad within the
shell, a laminated fabric pad against the inner cushion pad and
extending beyond the ends of the shell, the fabric pad being
adapted for contacting a wearer; and straps for conforming the knee
pad to the shape of the wearer's knee. A method for making the knee
pad is also disclosed.
Inventors: |
Slautterback; E. Gerald (Coral
Springs, FL) |
Assignee: |
FLA Orthopedics, Inc. (Miramar,
FL)
|
Family
ID: |
27383343 |
Appl.
No.: |
09/777,577 |
Filed: |
February 6, 2001 |
Current U.S.
Class: |
2/24 |
Current CPC
Class: |
A41D
13/065 (20130101) |
Current International
Class: |
A41D
13/06 (20060101); A41D 13/05 (20060101); A41D
013/00 () |
Field of
Search: |
;2/455,22,16,24,911
;128/881,882 ;602/23,26,62-63 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Hale; Gloria M.
Assistant Examiner: Patel; Tejash
Attorney, Agent or Firm: Dougherty & Clements LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. patent application Ser.
No. 29/126,080, filed Jul. 7, 2000, and U.S. patent application
Ser. No. 29/126,081, filed Jul. 7, 2000.
Claims
What is claimed is:
1. A knee pad for protecting the human patella, comprising:
(a) an outer shell constructed of a first polymeric material having
a first durometer;
(b) an inner shell pad juxtaposed with said outer shell, said inner
shall pad constructed from a second polymeric material having a
second durometer, said second duiometer being less than said first
durometer;
(c) a pad attached to said outer shell outer shell and extending
outwardly from said shell, said pad being adapted for contacting a
wearer; and
(d) means for conforming said pad and attaching said pad to the
wearer's knee.
2. A knee pad for protecting the human patella, comprising:
a shell including:
a concave outer portion constructed of a first polymeric material
of a first durometer and having inner and outer surfaces, and
an inner portion constructed of a second polymeric material of a
second durometer, said second durometer being less than said first
durometer, and having inner and outer surfaces wherein said outer
surface of said inner portion is juxtaposed with said inner surface
of said outer portion such that a gaseous medium is not provided
between said inner and outer portions during use;
a pad attached to said shell and extending outwardly from said
shell, said pad adapted for conforming about a wearer's knee;
and
a first attachment means attached to said knee pad for releasable
attaching said knee pad to the wearer's knee.
3. The knee pad according to claim 2, wherein said inner portion is
compressed between the patella and said outer portion when said
knee pad is worn by the wearer, and wherein said outer portion is
of a sufficient hardness to be resistant to wear, and wherein said
inner portion is of a hardness that is adapted for cushioning and
conforming to the contour of the patella of the wearer.
4. The knee pad according to claim 2, wherein said knee pad is
configured so that a significant portion of external forces which
are applied to said outer portion are dispersed across the patella
when worn.
5. The knee pad according to claim 2, wherein said inner and outer
portions each include a generally circular upper end and an
elongate lower end integral with, and contiguously extending from,
said upper end, wherein a rim of said outer portion upper end is
configured to generally encircle a patella of a wearer, and wherein
said lower end is configured to cover the patellar tendon between
the tibia and patella when worn by the wearer.
6. The knee pad according to claim 5, wherein said upper end of
said outer portion includes a recess, and wherein said inner
portion is at least partially disposed within said recess.
7. The knee pad according to claim 6, wherein said recess has a
depth in the range of approximately 1/4 to 2 a thickness of said
outer portion.
8. The knee pad according to claim 6, wherein said lower end
includes a recess which is contiguous with said upper end recess,
and wherein said inner portion is substantially disposed within
said upper and lower end recesses.
9. The knee pad according to claim 8, wherein said inner portion
has the same general shape as said first upper and lower recesses
and substantially fills said recesses.
10. The knee pad according to claim 9, wherein said outer surface
of said inner portion is generally flush with the inner surface of
said outer portion such that said inner portion such that said
inner portion does not substaintially extend beyond said
recesses.
11. The knee pad according to claim 9, wherein said outer and inner
portions are made from a material selected from the group
consisting of: TPE, urethane, polyurethane, polypropylene,
polyamide, and nylon, and wherein said outer portion is
sufficiently pliable to at least partially conform to the wearer,
and wherein said inner shell portion conforms to the patella when
worn by the wearer.
12. The knee pad according to claim 11, wherein said pad is made
from a material selected from the group consisting of: ethylene
vinyl acetate foam, urethane foam, or neoprene rubber.
13. The knee pad according to claim 11, wherein the knee pad is
configured so that the patella of the wearer partially extends
within said upper recess when said knee pad is worn.
14. The knee pad according to claim 8, wherein the inner portion is
compressed between the patella and said outer portion and is
adapted to conform to the contour of the patella and to the
patellar tendon between the tibia and patella of the wearer when
worn by the wearer.
15. The knee pad according to claim 14, further including a pair of
tabs extending from said lower end of said outer portion and a
second attachment means attachable to said tabs for attaching said
knee pad to the wearer.
16. The knee pad according to claim 15, wherein said first
attachment means is securable around a leg of the wearer above the
patella and the second attachment means is securable around the leg
of the wearer below the patella.
17. The knee pad according to claim 16, wherein said outer portion
is semi-rigid.
18. The knee pad according to claim 17, wherein said outer portion
is sufficiently pliably that the tabs conform to the wearer when
said second attachment means is secured around the leg of the
wearer.
19. The knee pad according to claim 18, wherein a hinge is
integrally formed within said pad above said shell, wherein said
hinge bends in concert with bending of the wearer's knee such that
said knee pad stays at a fixed position on the wearer when in
use.
20. The knee pad according to claim 19, wherein said hinge includes
a series of generally parallel grooves formed in said pad, and
wherein a thickness of said pad at said grooves is less than a
thickness of said pad adjacent to said grooves.
Description
FIELD OF THE INVENTION
The present invention relates to knee pads for protecting the
patella of a human being and to manufacturing methods for such knee
pads.
1. Background of the Invention
Industrial kneepads are used in a variety of occupations that
require occasional to continuous kneeling. Typical users of
kneepads include baggage handlers, carpenters, roofers, tile
installers, and carpet layers. Any person who is required to kneel
for an extended period of time runs the risk of injuring his or her
kneecap (patella). Some of the common knee injuries (Patellar
Subluxation, Knee Contusion, and Bursitis, Chrondromalacia Patella
Syndrome) are caused by weight, pressure, and twisting at the
knee.
Kneepads are designed to reduce the chance of injury and to provide
comfort to the user while kneeling. Typical kneepads are big and
awkward and have a tendency to migrate down the legs. The most
common kneepads are made of a closed cell foam that is cut into
shape and placed in a cloth pouch that is attached to a plastic
knee cup. Kneepads are usually fastened with elastic or webbing
straps. Kneepads provide padding to the knee while the plastic
kneecap provides swivel and sliding action, taking friction off the
patella.
2 . Description of the Prior Art
Knee pads are known in the prior art, which consists basically of
familiar and obvious structural configurations despite a large
number of knee pad designs which have been developed to meet
various objectives or requirements.
SUMMARY OF THE INVENTION
The present invention is a low-profile, shock absorbent knee pad
which offers the patella protection from pressure, weight, and
abrasion when kneeling for extended periods.
The invention utilizes two different ploymeric materials to form a
knee pad structure. The first material is a pliable yet durable
material which form the outer knee shell of the knee pad. The knee
shell provides the basic structure of the device. A second, softer
material is injected into a recess in the knee shell as an insert.
The second, softer material provides a cushioning surface into
which the user's knee can sink when in use. No blown foam is used
in the invented knee pad.
The preferred material for the knee insert is a thermoplastic
elastomer (TPE), and most preferably Santopreneg which is
especially formulated to be used in combination with polyamide or
polyurethane for applications where hard/soft combinations are
required. The preferred material for the knee shell is a Ethylene
Vinyl Acetate (EVA), especially formulated for molding flexible
articles.
The knee cup and insert are injection molded in a one step process.
These materials and processes permit the design of an
extraordinarily flexible and thin knee pad.
OBJECTS OF THE INVENTION
The principal object of the present invention is to provide an
improved knee pad for use by wearers who are required by their
duties to kneel frequently.
A further object of this invention is to provide a method of
manufacturing an improved knee pad.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects will become more readily apparent
by referring to the following detailed description and the appended
drawings in which:
FIG. 1 is a perspective view of a knee cup portion of the invented
knee pad.
FIG. 2 is a top view of the knee cup of FIG. 1.
FIG. 3 is a front view of the knee cup.
FIG. 4 is a left side view of the knee cup.
FIG. 5 is a rear view of the knee cup portion showing section
7--7.
FIG. 6 is right side view of the knee cup.
FIG. 7 is a cross-section view of the knee cup taken along line
7--7 of FIG. 5.
FIG. 8 is a bottom view of the knee cup.
FIG. 9 is a perspective view of the assembled knee pad in place on
a bent knee.
FIG. 10 is a top view of the assembled knee pad.
FIG. 11 is a front view of the assembled knee pad.
FIG. 12 is a right side view of the assembled knee pad of FIG.
11.
FIG. 13 is a rear view of the invented knee pad, i.e., from the
knee side.
FIG. 14 is a left side view of the assembled knee pad.
FIG. 15 is a bottom view of the assembled knee pad.
DETAILED DESCRIPTION
Referring now to the drawings, and particularly to FIG. 1, a
perspective view of a knee cup portion 10 of the invented knee pad,
the outer shell 12 of which is visible in this view. One of the
achievements of this invention is a slim profile of the knee cup.
The slim profile enables the wearer to walk upright in comfort as
well as perform kneeling tasks. The outer shell 12 is achieved by
molding a polymer, for example, polyurethane with a pliable surface
giving a rubber-like feel. The knee pad shell 12 may be polished in
a number of ways depending upon application. For instance, the
shell may be produced with a highly polished mold to allow the knee
pad to slide, or the shell may be produced with an unpolished mold,
which causes the finished shell to have a non-skid surface.
FIGS. 3 and 5 show a front plan view of the knee cup 10. The lower
portion of the cup contains two fastening points 16 where straps 20
(FIG. 9), that surround the upper leg and hold the knee in place,
are joined. The pliable material permits the shell 12 to conform to
the shape of the wearer's knee, insuring no gaps. The knee pad is
fabricated in two steps. The knee cup 10, illustrated in FIGS. 1 to
8 is fabricated in a single molding process. A soft cushioning
polymer, preferably a thermoplastic elastomer (TPE) such as
Santoprene.RTM. , or alternatively a urethane based compound or
other compound having similar physical properties to
Santoprene.RTM. is injection molded in a single step that forms the
insert 14 shaped to fit the patella and the harder TPE, urethane,
polyurethane, polypropylene, nylon, or the like, forming the outer
shell 12. The dampening insert material 14, may alternatively be
pour molded or lay-in laminated to the outer shell 12.
The durometer of the Santoprene.RTM. is adjusted to provide a soft
pad 14 that the wearer's knee can deform in such manner that the
device is substantially fitted to the individual wearer's patella
for comfort and performance under impact. The formed knee cup 10 is
joined to the rest of the device by sewing along an indentation 22
along the periphery of the knee cup 10 on the side opposite the
insert 14. FIG. 7 is a cross-section view of FIG. 5. The knee cup
10 is shown to be comprised of a polyurethane outer shell 12 and a
Santoprenes insert 14. After molding both the outer shell 12 and
the insert 14 are pliable. FIGS. 2 and 8 show the concave shape of
the cup 10 which is thin compared to existing knee pads. Ethylene
Vinyl Acetate is injection molded on both sides to yield a finished
appearance.
FIGS. 12 and 14 show a cushioning base 29 for placement between the
knee cup 10 and wearer and extending outwardly from the knee cup
10. Although not to be so limited, the cushioning base 29 is formed
of a pad 31, an inner material 24, and an outer material 30. The
cushioning base 29 is affixed to the knee cup 10. The pad 31 is
preferably an EVA or urethane foam to provide suitable cushioning
and comfort. Alternatively, the pad 31 can be constructed of a
specialty open or closed neoprene rubber blends. The outer material
30 preferably laminated to the pad 31 and made of nylon Nylon
Cordura, a tough, durable thick canvas like cloth that is stain
proof, and holds moisture. Similar high strength materials having
properties similar to Cordura may be used in the alternative. The
inner material 24 is preferably laminated to the pad 31 for
placement against the wearer. Preferably the inner material 24 is
flannel: chosen for the softness of flannel which may come in
direct contact with the wearer's skin. As illustrated in FIGS. 9
and 11, the outer material 30 is provided with attachment points 26
for sewing a second strap 28 which fits above the wearer's
knee.
As illustrated in FIG. 9, a series of grooves 33 are compression
formed in the pad 31 between the knee cup 10 and the second strap
28 to form a hinge which allows the knee to easily flex so that the
cushioning base 29 flexes in concert with normal knee movement.
Referring now to FIG. 1, the outer shell 12 of knee cup 10, is
shown, The outer shell 12 of knee cup 10 has a substantially
circular upper portion with a lower portion extending downward
therefrom. The lower portion of the outer shell 12 has two
extending members which extend opposite of one another, each
extending member having a hole therein such that the extending
member may be used as a fastening point 16. Referring to FIG. 3,
the outer shell 12 defines an indentation 22 along its entire
periphery, such indentation being of a depth of approximately one
fourth to one half of the thickness of the outer shell 12, with a
width approximating its depth. Referring to FIGS. 4 and 6, the
extensions which form fastening points 16 are preferably slightly
angled backwards.
Referring now to FIGS. 5 and 7, the rear side of outer shell 12
defines rear indentation 32. Rear indentation 32 has a depth equal
to one quarter to three quarters the thickness of outer shell 12.
Rear indentation 32 has an upper portion which is substantially
circular and resides within the substantially circular upper
portion of the outer shell 12. The lower portion of rear
indentation 32 is an elongate section extending downwards from the
rounded upper indentation 32 and is defined by and within the lower
section of the rear surface of outer shell 12. Further referring to
FIGS. 5 and 7, the inner cushion pad 14, also referred to as the
insert 14, is of the same general shape as the rear indentation 32
formed within the rear surface of outer shell 12, and insert 14
substantially fills the rear indentation 32 such that the rear
surface of outer shell 12 is even with the rearward facing surface
of insert 14.
Referring now to FIGS. 9-15, the cushioning pad 29 is fixedly
attached to the knee cup 10 by sewing the cushioning pad 29 to the
knee cup 10 along indentation 22 of the knee cup 10. As shown in
FIG. 11, the cushioning pad 29 has an upper portion 41 having
attachment points 26, a middle portion 42 providing for the hinged
movement of the upper portion from the lower portion, and a lower
portion 43. The outer surface of the lower portion 43 of the
cushioning pad 29 outer fabric pad 30 is sewn directly to the knee
cup 10 about indentation 22. As shown in FIG. 1l, the cushioning
pad 29 is continuous and covers the rear side of the knee cup 10.
Prior to connection to a human leg, the strap 20 is connected from
one fastening point 16 to the opposing fastening point 16, and the
second strap 28 is connected from one attachment point 26 to the
opposing attachment point 26.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
From the foregoing, it is readily apparent that I have invented an
improved knee pad for use by wearers who are required by their
duties to frequently kneel, and a method of manufacturing such
improved knee pad.
It is to be understood that the foregoing description and specific
embodiments are merely illustrative of the best mode of the
invention and the principles thereof, and that various
modifications and additions may be made to the apparatus by those
skilled in the art, without departing from the spirit and scope of
this invention, which is therefore understood to be limited only by
the scope of the appended claims.
* * * * *